Composition shake panel



Mach 21 1950 c. F. HUMBLE COMPOSITION SHAKE PANEL 2 Sheets-Sheet 1 Filedon. 2, 194

INVENTOR. HUMBLE CHARLES F.

. llulllllullll ATTORNEY Man'clh 21, 1950 c. F. HUMBLE 2,501,221

COMPOSITION smxg PANEL Filed. 001;. 2, 1.948 2 Sheets-Sheet 2 INVENTOR.CHARLES F HUMBLE ATTORNEY Patented Mar. 21, 1950 COMPOSITION SHAKEPANEL.

Charles F. Humble, St. Helens, reg., assignmto Western InsulatedProducts, Inc., St. Helena, -Oreg., a corporation of DelawareApplication October 2, 1948, Serial No. 52,459

Claims. (Cl. 205) One of the objects of this invention is to provide animproved fabricated exterior wall surface panel which will be im erviousto moisture while still retaining the insulating properties of modernwall boards.

Another object of this invention is to provide an improved exterior wallpanel which will not only have a surface finish giving the generalappearance of a shingle or shake surface, but, unlike otherprefabricated siding materials which attempt to achieve a similareffect, will actually provide for the horizontal rows of lapped boardscharacteristic of shakes and shingles instead of merely simulating suchlapped surfaces.

A further object of this invention is to provide an imitation shakepanel especially adapted to form an improved horizontal lappedjoint'with a companion panel in such manner that the resulting lappedjoint will constitute a tighter and more weather-proof seal than isobtainable with actual lapped shakes or the like.

. An additional object of this invention is to provide an improvedprefabricated panel which will be strong and durable and simple and easyto use in any exterior wall construction.

The manner in which these objects and other advantages are attained, themanner in which my improved imitation shake panel is made, and themanner in which the panel is used in constructing the desired wallsurface, will be explained in the-following brief description. In thisdescription reference is made to'the accompanying drawings in which:

Fig. 1 is a front elevation of one end portion of my panel;

Fig. 2 is an enlarged fragmentary sectional perspective view taken online 2--2 of Fig. 5;

Fig. 3 is an enlarged side or end elevation of the panel taken from theleft of Fig.1 as indicated by the line 33 of Fig. 1;

Fig. 4 is a corresponding fragmentary perspec tive view of the upperportion of the panel taken fromthe same end or side;

Fig. 5 is a front elevation of the face view of a portion of threepanels in position on a wall;

Fig. 6 is an enlarged fragmentary vertical section taken on line 6-6 ofFig. 5; and

Fig. 7 is a top plan view of a panel.

The body l0 (Fig. 2) of my panel is rectangular and is formed of wallboard, such as the fiber insulating wall boards which are now beingextensively used for inside walls and which are available on the marketunder such trade names as Fir-Tex, Celotex and the like. While fiberinsulating boards of various thickness and size may be employed in myinvention, I prefer to use a board of approximately one-half inch inthickness, about fifteen inches in height or slightly more thanthelcustomary exposed length of the shake surface on a shake-coveredexterior wall, and any convenient panel width, as for example four feet.One of the side edges of the panel body is formed with a recess l l(Figs. 4 and '7) in one face and the other side edge has a correspondingand similar recess 12 in the opposite face. Both recesses are of equaldepth. thus the depth being approximately equal to of the thickness ofthe body portion, thus for example, the depth of each recess beingapproximately inch. The purpose of these corresponding recesses orrabbets at the side edges, as will be apparent, is to provideoverlapping flush joints along the side edges between adjacent panelswhen the panels are set in place on the wall.

The top and bottom edges of the panel body are also formed with oppositerecesses or rabbets l3 and I4 respectively (Fig. 3). These recesses areof less depth than the recesses II and I2 at the sides and preferablywhen my panel is made in the thickness above mentioned,-the recesses l3and M will be only approximately A the depth of ,the recesses at theside and thus will have a depth of approximately of the thickness of thepanel body, for example, inch.

When the panel body ID has been formed with the four edges recessed orrabbeted as above described, the body is given a complete water-proofcoating in a bath of hot, quick-drying asphalt. Such coating over theentire body is indicated by the reference character 15 in the drawings.It it important in the carrying out of my invention not onlythat thiswater-proof coating cover the entire surface of the panel body if),including both faces and all edge surfaces, but also that thiswater-proof asphalt coating be confined to the surface and that thecoating operation be done with a quick-drying asphalt; for example, witha One or the faults 1 have found with other wall boards which have beenprefabricated for external wall surfaces is that apparently it has beenconsidered necessary to have such external wall board entirelyimpregnated with water-proof asphalt or similar compounds. Such complete1111- pregnation, by filling up the interstices in a fibrous wall boardcauses a substantial loss in the insulating value of the wall board. onthe other hand if the water-proof coating is properly applied in themanner I have described, the high insulating property of the fiber boardbody of the panel will be retained, and at the same time since thewater-proofing has covered the entire surface, the treated body In of mypanel will be suiliciently impervious to moisture both from the outsideor the inside of the wall. This high moisture-proofness, together with ahigh insulating value are important features in my external wall panel.

When the water-proof coating [5 has become hard and dry the coated panelbody ,is given a thick second coating it with a heavier, slower dryingasphalt. This second coating l5, for which an air-blown higher meltingpoint asphalt is preferably used, is confined to the front face of thepanel and does' not extend over the side recms H or over the top recessl3. Furthermore, a top horizontal marginal strip I1 is left at the topof the front face of the panel below the recase I! from which thissecond coating I6 is also excluded. The reason for this will becomeapparent later.

While this second coating I6 is still soft, a covering of comminutedgrit or granules of the desired color for the finished surface isapplied to the second coating and pressed into the same. Finally thiscoated front face is brought into contact with an embossing roll orrolls by means of which lines It simulating the grain lines in a woodenshake, are formed in the grit-covered asphalt, and at the same timedeeper and broader grooves i9, parallel to the side edges of the panel,being spaced preferably at irregular distances,

simulating the vertical lines between adjacent shakes on a shake-coveredwall, are pressed into this final coating. After this embossing hastaken place the panel is thoroughly cooled by being subjected to coldwater and/or cold air, whereupon the panel is ready for immediate use orshipment.

Figs. 5 and 6 illustrate the manner in which my panels are employed toprovide the desired imitation shake surfacing. The panels are applied inhorizontal rows, the panels in each row forming lapped fiush joints witheach other, by the overlapping rabbets ii and i2 at'the side edges, andthe panels of one horizontal row bein preferably staggered in relationto the panels of the horizontal row below.

The width of the marginal strip ll along the top of the panel is madeexactly equal to the width of the recess or rabbet H at the bottom ofeach panel. Consequently the bottom rabbets ll of one row of panels willexactly cover the marginal strips il along the top of the next lower rowof panels. The fact that the second coating of asphalt with its gritsurfacing does not extend into the marginal strip l1, enables the underside of the bottom rabbet ll of a panel in the next row to fit tightlyagainst the opposed face of the marginal strip ll. This would not be thecase if the'embossed and grit surface extended between these two opposedfaces of the adjacent horizontal rows. Furthermora'this tight sealoverlap between the horizontal rows is continued between the face of thetop rabbets I3 and the rear face of the panels in the next row above.Thus, in effect, a double seal is provided at the overlapped butt jointsof the imitation shakes. This is another important feature of my panel.

While an extensive overlap between the horizontal rows of panels couldalso be formed by omitting the top rabbet l3 and increasing the width ofthe marginal strip l1 and width of the bottom rabbet I! by an amountequal to the width of the omitted top rabbet, this would be lessdesirable since such a wide rabbet at the bottom of the panel wouldweaken the panel and present the. possibility that such extra widebottom rabbet might crack or break off from the panel body if subjectedto excessive strain. Also, the

stepped overlap formed with the rabbets l3 and I4 arranged as shown inFig. 6 makes a better weather proof seal than an overlap confined toasingle plane. I

Thus my improved exterior wall panel not only simulates the exposedfaces of shakes but also provides for the actual overlap resembling thebutt overlap joints of shakes; and at the same time it provides anexceptionally tight and weather proof seal at such overlapped joints. Asapparent, my wall panel is very easily and quickly mounted in positionon the wall to be covered. Preferably it will be applied over an undersurfacing of the customary sheathing. However, for cheaper or temporarybuilding construction the panel may, if desired. be applied directly tothe studding, and due to the moisture proofness, insulating quality, andtight joints provided, my panel will make a very satisfactory externalwall even when applied directly to the studding for inexpensive buildingconstruction.

The limitation shake panel can of course be made in various sizes andthicknesses. The size and thickness which I have described is merelyillustrative. Thus if. larger, heavier shakes are to be imitated mypanel would correspondingly be wider and thicker. The thickness of thepanel body will of course be determined largely by the simulated shakebutt thickness desired to be presented, the upper and lower rabbetsbeing given that approximate thickness and the remaining body portion ofthe panel made suillciently thicker .to provide for suitable cooperatingsurfaces to constitute-the double overlap joint for the simulated butts.

Various surfacing and water-proofing materials could be used in theformation of my panel and modifications could be made in its structurewithout departing from theprinciple of my in- .vention. The particularmaterials mentioned I have found to be very satisfactory in themanufacture of my panel; but my invention is not to be understood aslimited otherwise than as set forth in the claims.

I claim: 1. A composition shake panel including a sheet of fibrousinsulating board having oppositely disposed rabbets extending from therear and front faces at the head and butt edges respectively,

76 the top of the front face of said panel, the width of said marginportion corresponding to the width of said butt edge rabbet, said outersurfacing excluded from said margin portion, whereby when said panelsare applied to a wall the butt rabbets of one horizontal row of panelswill extend over said margin portions in the next lower row of panelsand form weather tight butt joints having a double overlap.

2. A composition shake panel including a sheet of fibrous insulatingboard having oppositely disposed rabbets extending from the rear andfront faces at the head and butt edges respectively, said rabbets havinga thickness greater than half the thickness of said sheet, the surfaceof said sheet entirely covered with a water-proofing coating, saidwater-proofing confined to the surface portions of said sheet so as notto reduce extensively the insulating property of said sheet, an outerheavy, shake-simulating surfacing on the outer exposed face of thepanel, and a margin portion extending across the top of the front faceof said panel, the width of said margin portion corresponding to thewidth of said butt edge rabbet, said outer surfacing excluded from saidmargin portion, whereby when said panels are applied to a wall the buttrabbets of one horizontal row of panels will extend'over said marginportions in the next lower row of panels and form weather tight buttjoints having a double overlap.

3. An external wall panel of the character described comprising arectangular sheet of fibrous insulating board of not less than inch inthickness, having oppositely disposed rabbets extending from the rearand front faces at the head and butt edges respectively, said rabbetshaving a thickness of not less than inch, oppositely disposed rabbets atthe side edges of said sheet, said side rabbets having athicknessapproximately equal to half the thickness of said sheet, the surface ofsaid sheet impregnated with a waterproofing coating, said impregnatedwater-proofing confined to the surface portions of said sheet so as notto reduce extensively the insulatin property of said sheet, an outerheavy, shake-simulating surfacing on the outer exposed face of thepanel, said outer surfacing consisting of heavy water proof materialwith comminuted grit applied thereon and embossed with lines simulatingshakes, and a margin portion extending across the top of the front faceof said panel, the width of said margin portion corresponding to thewidth of said butt edge rabbet, said outer surfacing excluded from saidmargin portion.

4. An external wall panel of the character dehead and butt edgesrespectively, said rabbets having the same thickness, oppositelydisposed rabbets at the side edges of said sheet, said side rabbetshaving a thickness approximately equal to half the thickness of saidsheet, the surface of said sheet entirely covered with a waterproofing,quick-drying asphalt solution, an outer heavy, shake-siinulatingsurfacing on the outer exposed face of the panel, said outer surfacingconsisting of heavier, slower drying, water proof asphalt withcomminuted grit applied thereon and embossed with lines simulatingshakes, and a margin portion extending across the top of the front faceof said panel, the width of said margin portion corresponding to thewidth of said butt edge rabbet, said outer surfacing excluded from saidmargin portion, whereby when said panels are applied to a wall the buttrabbets of one horizontal row of panels will extend over said marginportions in the next lower row of panels and form weather tight buttjoints having a double overlap.

5. A composition shake panel comprising a rectangular sheet of fibrousinsulating board of not less than inch in thickness, having oppositelydisposed rabbets extending from the rear and front faces at the head andbutt edges respectively, said rabbets having the same thickness and athickness approximately equal to that of a shake butt, oppositelydisposed rabbets at the side edges of said sheet, said side rabbetshaving a thickness approximately equal to half the water-proofingconfined to the surface portions of said sheet so as not to reduceextensively the insulating property of said sheet, an outer heavy,shake-simulating surfacing on the outer exposed face of the panel, saidouter surfacing consisting of heavy water proof material with comminutedgrit applied thereon and embossed with lines simulating shakes, and amargin portion extending across the top of the front face of said panel,the width of said margin portion corresponding to the width of said buttedge rabbet, said outer surfacing excluded from said margin portion,whereby when said panels are applied to a wall the butt rabbets of onehorizontal row of panels will extend over said margin portions in thenext lower row of panels and form weather tight butt joints having adouble overlap.

CHARLES F. HUMBLE.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 837,310 Crabbe Mar. 2, 18861,202,770 Aycock Oct. 31, 1916 2,078,039 Stoner Apr. 20, 1937

